Break-down pallet and method of use

ABSTRACT

A pallet and method of use are provided for carry large quantities of materials for shipping. The pallet is configured to be divided into smaller sub-pallets, such that the pallet can be broken down, or otherwise subdivided, into smaller, more usable sub-pallets containing job lot quantities. Each sub-pallet may comprise decking and one or more skid blocks attached underneath the decking. Stringer boards may be attached to each of the sub-pallets to hold the sub-pallets relatively together. These stringer boards may be removable from each of the sub-pallets so that each of the sub-pallets can be separated from one another.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.60/645,259, filed Jan. 20, 2005, the entirety of which is herebyincorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Preferred embodiments of the present invention relate to the palletindustry, more specifically, pallets for trim products.

2. Description of the Related Art

In a building and construction market once dominated by wood, and thenvinyl, fiber cement is beginning to gain a significant presence.Previously, in order to complete a home with trim, only traditionalmaterials such as wood and vinyl were available. Recently, James HardieBuilding Products has worked on introducing a fiber cement trim tocomplete a house with a full-wrap of fiber cement warranted exteriorproducts. Such materials include Hardiplank® lap siding, Hardishingle™siding, Hardipanel® vertical siding, Hardisoffit® soffit panels, andHarditrim® trim planks.

In most residential housing building sites, materials are delivered tothe site in predetermined quantities for each specific house ordevelopment stage. The main medium for transporting siding, trim,fascia, soffit, etc. is by way of pallets, more specifically woodenpallets. When exterior products are manufactured, they are typicallyfastened to and transported in large quantities on pallets. Because theproducts are typically shipped in large quantities on large pallets, itis the job of the distributor to break down the materials intomanageable sizes requested by the contractors.

For example, when trim planks, such as Harditrim® XLD® trim planks, aremanufactured, the amount of trim stacked onto a pallet is often enoughto finish off approximately 8-10 houses. This is done for economicreasons to the manufacturer; however, it also creates work for thedistributor to take the pallet apart and supply the contractor with therequired footage. The distributor then, typically, throws the trim ontop of pallets that may carry other materials, such as siding. Becausethese other materials, such as siding, may have greater flexibility thanthe trim, the siding may tend to sag toward their ends underneath thetrim. The more rigid trim is usually bound together with the sidingusing straps or other means. As the underlying siding provides littlesupport for the trim, once the materials are bound some of the trim mayflex and break during transportation. What is needed is a way to shipsmall (job lot) quantities of trim planks such as Harditrim® XLD® trimplanks, and other building products, to construction sites withoutcausing damage to the product.

SUMMARY OF THE INVENTION

One way to ameliorate some of the above-mentioned disadvantages is toprovide a pallet configured to carry large quantities of materials forshipping, which is further configured to be divided into smallersub-pallets. Accordingly, one embodiment of the present invention is amanufactured pallet that can be broken down, or otherwise subdivided,into smaller, more usable sub-pallets containing job lot quantities.Another embodiment of the present invention is directed to a method ofseparating a larger manufactured pallet into smaller, more usablesub-pallets for particular jobs.

Another embodiment of the invention is directed to a method of easilyseparating the sub-pallets.

In one embodiment, a pallet is provided comprising a plurality ofsub-pallets. Each sub-pallet comprises decking and one or more skidblocks attached underneath the decking. One or more stringer boards isattached to each of the sub-pallets, holding the sub-pallets relativelytogether. The one or more stringer boards are removable from across theskid blocks of each of the sub-pallets so that each of the sub-palletscan be separated from one another.

Preferably, the decking comprises a plurality of decking boards.Stringer boards may be provided at either end of the decking and in someembodiments, are provided at both ends of the decking. Additionalstringer boards may also be provided between the ends of the decking. Aplurality of skid blocks may be attached underneath the decking. In oneembodiment, the stringer boards are attached to each of the sub-palletsusing smooth pallet nails.

In another embodiment, a method of transporting material is provided. Apallet is provided supporting said material. The pallet includes aplurality of sub-pallets attached by stringer boards, each of thesub-pallets supporting a portion of the material. The stringer boardsare removed from the sub-pallets, and each of the sub-pallets isseparated from one another. Each sub-pallet can then be individuallytransported for a particular desired use.

Preferably, removing the stringer boards comprises removing smooth shanknails connecting the stringer boards across each of the sub-pallets.Each of the sub-pallets may include decking and skid blocks underneaththe decking. In one embodiment, each of the sub-pallets supports trimmaterial. The method may further comprise banding together the portionof the material on each of the sub-pallets.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view showing a pallet according to oneembodiment of the present invention.

FIG. 1B is a schematic view showing the pallet of FIG. 1A.

FIG. 2A is an end view of another embodiment of a pallet, withoutshowing the stringer boards attached.

FIG. 2B is a side view of the pallet of FIG. 2A, showing the stringerboards attached.

FIG. 2C is an enlarged view of the end of a stringer board of FIG. 2B.

FIG. 3 is a flow chart illustrating a method of separating amanufactured pallet into sub-pallets.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

One embodiment of the present invention is a pallet, preferably madefrom wood, that is able to be broken down into 3 smaller job lot palletsfor delivery to construction sites from the distributor without causingdamage to the building product being delivered. In one embodiment, thepallet is adapted for delivery of trim. It will be appreciated that thepallet can be broken down into a fewer or a greater smaller job lotpallets, as desired. It will also be appreciated that any viable palletmaterial can be used, including, but not limited to, wood, plastic,metal, plastic or wood composite and any combination thereof. Of course,different components of the pallets can each be manufactured ofdifferent materials, if desired.

FIGS. 1A and 1B illustrate a break-down pallet 100 according to oneembodiment of the present invention. The pallet 100 includes skid blocks110, decking 120, and stringer boards 130. The decking 120 preferablycomprises a plurality of elongated boards, more preferably 12 boardsprovided side by side in parallel relationship with each other. In oneembodiment, each of the decking boards is 1″×4″×10′ in dimension. Inanother embodiment, the decking boards can have varying widths, forexample, between about 2″ and 12″, more preferably between about 3″ and4″, more particularly, 3″ or 3½″. The decking can be longer or shorter,for example, between about 6′ and 12′, or can be even longer or shorter,to accommodate different sized building materials. For example, thedecking can be as short as about 2′ to capture smaller items such asboxes. Further details are described below.

In one preferred embodiment, the decking boards are preferably dividedinto three sets having four decking boards 120 each. Each set of deckingboards 120 preferably makes up a sub-pallet 140, 150 and 160. Thedecking boards 120 of each sub-pallet can be spaced from each other, orcan be placed flush against each other. Each of the sub-pallets can alsobe spaced from each other, or can be flush against each other. The skidblocks 110 preferably comprise a plurality of elongated boards, gluts,peeler cores or round timbers, or similar structure (such terms beingused interchangeably herein), arranged in generally transverserelationship with the decking boards 120. As illustrated in theembodiment of FIGS. 1A and 1B, each set of decking boards 120 has fiveskid blocks 110 attached to an underside of the decking boards 120, withtwo adjacent the ends and three in between. Fewer or greater numbers ofskid blocks 110 may be used depending on the length or size of thematerial being shipped. Standard pallet nails may be used to attach thedecking 120 to the skid blocks 110, although it will be appreciated thatother fasteners, such as screws, may be used. Accordingly, in thisembodiment, 15 total skid blocks 110 are provided. In one embodiment,each of the skid blocks is 4″×4″×14″ in dimension. The skid blocks 110may be of any appropriate dimension suitable for use with a desirednumber and size of decking 120.

In the illustrated embodiment, a stringer board 130 is preferablyattached to the skid blocks 110 at each end of the decking, as shown inFIGS. 1A and 1B. In one embodiment, the stringer boards 130 are2″×4″×47″ in dimension. The stringer board 130 is preferably attached tothe three skid blocks at each end of the decking, preferably using sixsmooth shank pallet nails across the skid blocks.

In one embodiment, each sub-pallet is adapted to support 30 to 60 piecesof 4″ trim, with each sub-pallet holding four pieces of trim across itswidth, and stacked 15 pieces high. Thus, the whole pallet assembly mayhold 12 pieces of trim across and 15 pieces of trim high.

FIGS. 2A-2C illustrate another embodiment of a pallet capable of beingbroken down into sub-pallets. As with the embodiment of FIGS. 1A-1B, thepallet 200 comprises 12 decking boards 220 forming three sets orsub-pallets 240, 250 and 260, with each set being attached by separateskid blocks 210. The decking boards of this embodiment can each have thesame width. Alternatively, in one preferred embodiment, in eachsub-pallet the two center decking boards are 3½″ wide and the twodecking boards on each side are 3″ wide. The decking boards can be flushwith each other or have a gap, preferably up to about ¼″. Each of thesub-pallets may be spaced apart by between about ¼″ and 1½″, morepreferably by between about ½″ and 1¼″, and even more preferably byabout 1″.

As shown in the side view of FIG. 2B, four skid blocks (here in the formof round timbers 210) are provided along the length of the deckingboards 220, each skid block 210 provided generally transverse to thelength of the decking boards 220 and attached along an undersurface offour decking boards. Stringer boards 230 are provided adjacent each ofthe skid blocks 210, the stringer boards 230 extending generallytransversely across an undersurface of all twelve of the decking boards220. As illustrated, two stringer boards 230 are provided at the ends ofthe decking boards, with two additional stringer boards 230 providedbetween the two outer stringer boards, preferably 42″ from the outerstringer boards. Alternatively, the stringer boards 230 and timbers 210can be equally spaced from each other. Thus, in this embodiment, fourstringer boards 230 are attached to reinforce the pallet duringshipment, and accordingly, when the pallet is broken down, all fourstringers 230 should be removed. Preferably, the stringer boards 230 andthe skid blocks 210 provided at the ends of the decking boards arelocated right at or near the ends of the decking boards, for example, nomore than about 6″ from each of the ends. It will be appreciated thatalthough FIG. 2B illustrates the skid blocks located to the inside ofthe stringer boards, they can also be provided to the outside of thestringer boards.

As illustrated in the embodiment shown in FIGS. 2A-2B, when connectedtogether the whole pallet is 42″ by 120″ in dimension, with each skidblock (and consequently each sub-pallet) being 14″ long (or wide). Thestringer boards 230 of this embodiment may therefore be 42″ in length.Alternatively, the stringer boards may be longer or shorter, forexample, between about 36″ and 48″. It will be appreciated that thewhole pallet and each of the sub-pallets can have any suitable dimensionfor transporting material, and that the number of sub-pallets can differfrom three. Therefore, in alternate embodiments, two, four, five, six,seven, eight or more sub-pallets can be used. The number or length ofthe skid blocks may also vary. The length, for example, can be betweenabout 8″ and 24″, more preferably between about 12″ and 16″. It willalso be appreciated that for any given assembly of sub-pallets, each ofthe sub-pallets need not have the same dimension, so that somesub-pallets are wider than others. Additionally, the sub-pallets neednot all be attached parallel along a longitudinal edge. For example, asubstantially square pallet can be comprised of four smaller squaresub-pallets.

Referring to the embodiment of FIGS. 2A-2C, FIG. 3 illustrates onemethod of separating a pallet into sub-pack pallets, including the stepsof:

Step 310: Removing the Stringers

In this step, after the banding is removed from around the pallet andthe material on the pallet, the four stringers are completely removedfrom the sides of the round timbers. This can be done by using a hammeror pry-bar or any other means suitable for prying. Nailing is minimal onthe stringers (with roughly 6-10 smooth shank nails across eachstringer), so removal is preferably easily accomplished by a person,without requiring substantial mechanical force or assistance. Thus,nails or other suitable fasteners should be used that are sufficient tohold the stringers against the timbers during transport, but allow forremoval of the fasteners without excessive force. The pallet ispreferably elevated during this stage (preferably by at least 12 inches)using a forklift or pallet jack.

Step 320: Break Into Mini Pallets

In this step, after the stringers are removed, the pallet is set down ona flat surface. The forklift driver then reverses out until only about12″ of the forks remain under the pallet. Then the first mini orsub-pallet is elevated slightly (preferably about 3-4 inches) and movedaway from the other two sub-pallets. This step can be repeated for thesecond mini or sub-pallet.

Step 330: Reband Mini Pallets

In this step, the trim on the mini or sub-pallets are rebanded,preferably using corner protectors on the trim. Banding, which mayinclude metal or plastic straps or other suitable means, is preferablyat least put around each of the sub-pack pallet ends and one in thecenter.

Alternatively, the job lot quantities of trim can be primarily banded toeach sub-pallet by the manufacturer, thus creating job lot quantitiesalready banded to a sub-pallet. The banded job lot quantities can besecondarily banded together on the assembled sub-pallets. When bandedthis way by the manufacturer, the distributor need only remove thestringers and the secondary banding, thus leaving the job lot quantitiesbanded to the sub-pallets ready for delivery to work sites.

Advantageously, the preferred embodiments described above provide a wayto safely ship job-lot packs to the construction site without damagingthe product. These embodiments also provide a way to have a moreconvenient means of logistically gathering an order for thebuilder/contractor from the distributor. Furthermore, these embodimentsprovide a way to possibly capture more smaller/stocking dealers on thebasis they would have less risk of large quantities in inventory andbetter pricing.

The pallet described above, while being applicable for fiber cement trimproduct, can be used for any type of product whether it is buildingproducts (e.g., cladding), landscaping materials (e.g., retainingwalls), or materials that are shipped in boxes. Any material or productthat is broken down at the distributor from the manufacturer for furtherdistribution in bundles can use this design.

Although the foregoing invention has been described in terms of certainpreferred embodiments, other embodiments will become apparent to thoseof ordinary skill in the art, in view of the disclosure herein.Accordingly, the present invention is not intended to be limited by therecitation of preferred embodiments.

1. A pallet, comprising: a plurality of sub-pallets, wherein eachsub-pallet comprises decking and one or more skid blocks attachedunderneath the decking; and one or more stringer boards attached to eachof the sub-pallets and holding the sub-pallets relatively together,wherein the one or more stringer boards are removable from each of thesub-pallets so that each of the sub-pallets can be separated from oneanother.
 2. The pallet of claim 1, wherein the decking comprises aplurality of decking boards.
 3. The pallet of claim 1, comprisingstringer boards at either end of the decking.
 4. The pallet of claim 1,comprising stringer boards at both ends of the decking.
 5. The pallet ofclaim 1, comprising a plurality of skid blocks attached underneath thedecking.
 6. The pallet of claim 1, comprising stringer boards at eachend of the decking and additional stringer boards between the ends ofthe decking.
 7. The pallet of claim 1, wherein the stringer boards areattached to each of the sub-pallets using smooth pallet nails.
 8. Amethod of transporting material, comprising: providing a palletsupporting said material, wherein said pallet includes a plurality ofsub-pallets attached by stringer boards, each of said sub-palletssupporting a portion of said material; removing said stringer boardsfrom said sub-pallets; and separating each of said sub-pallets from oneanother.
 9. The method of claim 8, wherein removing said stringer boardscomprises removing smooth shank nails connecting said stringer boards tosaid sub-pallets.
 10. The method of claim 8, wherein each of saidsub-pallets includes decking and skid blocks underneath said decking.11. The method of claim 8, wherein each of said sub-pallets supportstrim material.
 12. The method of claim 8, further comprising bandingtogether the portion of said material on each of said sub-pallets.